SUCCESS STORY

DC-to-AC Conversion Program offers Energy Savings while maintaining Performance Needs

SITUATION A client approached TIGHE INDUSTRIAL employees with challenges related to an aging co-extruder application at their facility. Two of the three existing DC system extruders were having problems and in need of replacement. TIGHE employees recommended a conversion from the DC system to an AC system retrofit. The clients initial concerns were with the performance and low-end torque capability of an AC drive and motor for their specific needs, especially since these machines were running 24 hours a day for 7 days a week over 50 weeks a year. Those concerns were addressed with the appropriate AC platform recommendation by TIGHE employees. AC motors and drives offer many benefits over antiquated DC systems. Todays AC vector motors and drives achieve a 1000:1 torque versus DCs 10:1 ratio. The AC vector motor and drive also provide a more accurate speed control at 0.01% versus 0.5% with DC. SOLUTION With a focus on energy efficiency and reduced energy costs, TIGHE INDUSTRIAL employees provided this client with the data, equipment and experience to capitalize on energy savings and incentives - without sacrificing the performance required by the facility. TIGHE employees provided the new AC equipment and a turnkey start-up plan.

BEFORE

AFTER

BEFORE

AFTER

SUCCESS The switch from a DC to AC platform resulted in documented energy savings of more than $89,000 over the course of 10 months which more than paid for the upgrade investment.

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TIGHE INDUSTRIAL employees performed a complete pre- and postanalysis on energy usage on the clients A and B extruders: Pre- and Post-Analysis
Extruder A - 60hp BEFORE conversion to AC ESTIMATE after conversion to AC ACTUAL after conversion to AC Kilowatt Usage Power Factor Kilowatt Usage Power Factor Kilowatt Usage Power Factor 30.82kw 41% 20.6kw 90% 19.1kw 90% Extruder B - 600hp 285.2kw 55% 181.4kw 90% 157.22kw 90%

TIGHE INDUSTRIAL also, on behalf of the client, applied for energy rebates from the local utility provider resulting in a $28,000 rebate check for the client. The energy savings of $89,000, coupled with the rebate check, resulted in $117,000 in total savings.
TOTAL cost of upgrade to AC (parts, start-up, electrical) TOTAL savings (energy savings & rebate) RETURN ON INVESTMENT $94,000 $117,000 LESS THAN 10 MONTHS

For more information about DC-to-AC Conversion programs, call us toll-free at 877-879-1350.

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